Panel and lap joint made therefrom

ABSTRACT

An improved weatherproof joint formed from overlapping one panel of improved design with another panel wherein the opposing marginal side edges of the panels are provided in the joint area with improved interfitting and opposing corrugations which form a unique deep truss-like lap joint structure having improved loadbearing characteristics.

United States Patent Maurer 5] June 6, 1972 [54] PANEL AND LAP JOINTMADE 1,406,082 2 1922 Probert ..52 521 THEREFROM 2,073,706 3/1937Overholtz 1,912,486 6/1933 Krantz [72] Inventor: Joseph M. Maui-er,Concord, Calif. 3 7 03 sagendol-ph [73] Assignee: Kaiser Aluminum &Chemical Co 1,459,855 6/ 1923 Olden Oakland, l Kramer X 22 Filed: Mar.30, 1970 Primary Examiner-Frank L. Abbott App]. No.: 23,743

Assistant ExaminerHenry E. Raduazo AttarneyJames E. Toomey, Paul E.Calrow, Harold L Jenkins and John S. Rhoades [57] ABSTRACT 10 Claims, 6Drawing Figures PATENTEDJUH 8l972 3,667,185

SHEET 2 OF 2 dosspn M. M40252 mvsn/roz PANEL AND LAPJOINT MADE THEREFROMBACKGROUND OF THE INVENTION This invention relates to panels and thejoints formed therebetween. More particularly it is concerned withproviding an improved building panel and the joint formed by overlappingone such panel with a similarly shaped panel in a building installation.

Various building panels have been devised in the past which areoverlapped to provide weatherproof lap joint structures therebetween.Examples of such panels and lap joint structures are shown in U.S. Pat.Nos. 2,073,706 to Overholtz granted Mar. 16, I937, and U.S. Pat. No.2,130,189 to Lawrence et al. granted Sept. 13, 1938. Although prior artbuilding panels, such as those shown in the aforesaid patents, havemarginal side edges of different configurations-whereby they can beoverlapped to form a lap joint, the wall structures and crests of theoverlapped corrugations on opposing marginal edges of the panels werenot such that when the panels were installed and the corrugationsoverlapped they provided a weatherproof joint assembly which hadrelatively deep trusslike structural and functional characteristics. Therelatively deep truss-like structure in the joint area of the panels ofthe instant invention makes the panels capable of withstanding severeloads of various kinds as well as providing readily nailable surfacesand a substantially weatherproof structure in the joint area.

SUMMARY OF THE INVENTION It is the primary purpose of the instantinvention to provide an improved building panel having uniquecorrugations or ribs along the opposing marginal side edges thereofwhereby the panel can bereadily interfitted and overlapped with anotherand preferably similarly shaped panel in such fashion that theweatherproof joint formed by the interfitting and overlapped panels wheninstalled on a building will have a relatively deep truss-likestructure. The resultant structural joint assembly is capable ofresisting various individual topside and lateral loads or combinationsthereof. It also provides improved nailing surfaces for nailing thepanels to a building structure even in those instances where thebuilding panels are made of relatively thin gauge materials.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a broken fragmentaryperspective view of a typical roofing or siding installation involvingthe principles of the instant invention; 1

FIG. 2 is an end elevational view of the overlapped panels shown in FIG.1 with parts added and other parts removed and when taken generallyalong the line 22 of FIG. 1;

FIG. 3 is an enlarged fragmentary end elevational view of the roofingjoint installation of FIG. 2 when taken within the circumscribing line 3thereof and discloses the manner in which the marginal side edges of apair of the improved building panels of the instant invention areoverlapped and nested to form the improved weatherproof lap joint of theinstant invention;

FIG. 4 is an end elevational view of a double crested corrugation thatforms one marginal edge of a panel of the instant invention;

FIG. 5 is an end elevational view of a portion of the panel of theinstant invention when taken within the encompassing line 5-5 ofFIG. 2;ancl FIG. 6 is a fragmentary perspective view of a typical buildingwherein the roof and walls are formed from panels of the instantinvention.

DETAILED DESCRIPTION With reference to the drawings, the lap joint orstanding seam l of the instant invention is used for roofing or sidingsheets or panels 10 that can be made from various light weight metalmaterials such as aluminum and other materials such as rugged polyesterand polyvinyl translucent plastic materials. Translucent plastic panelsare used advantageously with similarly shaped metal panels whenskylights or the like are needed in a roofing structure.

In a preferred embodiment of the invention, panels 10 when made of metalare advantageously made from a thin gauge aluminum base alloy in theextra hard temper range and designated as H-l9 metal. The metal can alsobe embossed with a suitable design, if desired. As used herein, the termaluminum base alloy" means an alloy containing at least 50 percent byweight of aluminum. One suitable aluminum base alloy of thin gaugematerial on the order of 0.01 8 t 0.001 and in extra hard temper can bea 5154 aluminum alloy, the chemical composition of which as listed withthe Aluminum Association is as follows:

Elements: 5 I54 Aluminum Alloy,

Percent l. Silicon plus iron 0.45 maximum 2. Copper 0.10 maximum 3.Manganese 0.10 maximum 4. Magnesium 3.l 3.9 maximum 5. Chromium0.15-0.35

6. Zinc 0.20 maximum 7. Titanium 0.20 maximum 8. Other elements, each0.05 maximum 9. Other elements, total 0.15 maximum 10. AluminumRemainder The panels 10 of aluminum sheet material are roll formed andwhen made of plastic materials are so molded whereby the opposed sidemarginal edges 12 and 14 of a panel are provided with improvedupstanding, double and single crested corrugations respectively. Byvirtue of such corrugations, the opposing side marginal edges ofsimilarly shaped panels can be readily overlapped and intemested to formthe novel and deep truss-like joint structure of the invention. Thus,during installation of panels 10 on the side or roof of a building, itis contemplated that the panels would be placed side by side such thatthe marginal side edge 14 of one panel 10 would be overlapped by theopposing marginal side edge 12 of a similarly shaped panel 10. Anindividual panel 10 will now be described in detail.

As indicated particularly in FIGS. 3 and 4, marginal side edge 12 of apanel 10 is provided with the double crested corrugation 16. Corrugation16 includes a primary and relatively narrow nailing crest or surface 18and a secondary and relatively wide corrugation or stiffening crest 20.Nailing crest 18 is connected to crest 20 by means of relatively shortdownwardly and outwardly inclined walls 22 which in the asmade panel arepreferably inclined at interior angles of about 60 to the normal planeof crest 20. This plane of crest 20 substantially parallels the medianplane M of panel 10 as well as the underside 24 of panel 10. Theextremities of crest 20 terminate in outwardly and downwardly projectingrelatively long sidewalls 25 which in the as-made condition of the panel10 are disposed at interior angles of about 65 to the median plane Mendbottom plane 24 of the sheet.

In one advantageous embodiment of the invention, however, and asindicated particularly in FIG. 4, outermost or free wall 25 of amarginal edge corrugation 16 can be slightly underbent inwardly duringpanel manufacture whereby it initially makes an interior angle ofapproximately 68 with respect to the median plane M of the sheet 10. Thepurpose of this underbending is to allow this wall 25 provided with endlip By virtue of the unique configuration of the double crestedcorrugation 16, a unique pocket 2 is provided in the upper portion ofthe corrugation which is adapted to snugly receive the top portion ofthe flat topped corrugation 32 that makes up the other marginal sideedge 14 of a panel 10.

As illustrated in FIG. 3, corrugation 32 is provided with a flat crestor top 34 and a pair 'of downwardly and outwardly inclined sidewalls 36which, in the as-manufactured condition of a panel 10, are preferablyarranged at interior angles of approximately 56 to the median plane Mand bottom of the sheet or panel with which they are associated. It isto be noted in any event that the interior angles of walls 36 are lessthan the interior angles made by the long walls 25 of a double crestedcorrugation 16 of the overlapping panel used in the joint structure 1shown in the various figures of the drawings.

.The outermost or free wall 36 of the corrugation 32 is also providedwith a lip portion 38, which during manufacture of panel 10 can be bentslightly upwardly a few degrees so that it can be tensioned against andmake excellent contact with the underside of the lapping panel 10provided with the lapping corrugation 16.

Successive. panels 10 are installed on the roof or side of a building bybeing arranged crosswise to a support, such as a rafter, beam, furringtype strip 40, etc., all as indicated in FIG. 3, and with marginal edge14 of one panel arranged to be overlapped by the marginal edge 12 of asimilarly shaped panel. As each standing seam or joint 1 is formed bythe lapping and overlapped edges 12 and 14 of adjacent panelsappropriate fasteners, such as nails 42, are driven completely throughthe nailing crest 18 of corrugation l6 and the flat crest 34 of theunderlying corrugation 32 that fits in pocket I: of the topmostcorrugation and into the support 40. The fasteners 42 can be providedwith standard neoprene washer elements 44, if desired, for sealing thenails in' place after being driven through the panels 10 making up thejoint.

As indicated in FIG. 3, wide crest 20 of double crested corrugation 16provides certain advantages during the aforesaid nailing operation aswell as in the final overall joint structure 1 formed by the panels.During nailing, the crest 20 provides a bearing surface and lateralsupport that resists overdriving of a nail 42 as well as distortion,buckling and collapse of the corrugations 16 and 32. After installationand during use crest 20 and walls 22 and 25 of corrugation 16 act inconjunction with top 34 and walls 36 of lapped corrugation 32 to form adeep truss-like joint structure capable of efi'ectively resistingextreme concentrated loads, such as those applied by walking on thesame, and extreme unifonn loads, such as those applied by winds,'snow,rain, etc. and various combinations of such loads even when the panels10 are made of relatively thin gauge materials as noted above. Theaforesaid loads are roughly indicated by the arrows in FIG. 3.

The deep truss-like joint structure 1 results from the particularconfiguration of the corrugations 16 and 32, the manner in which thecorrugations are uniquely lapped and interfitted as well as the largeinterior or steep rib angle of walls 25 of lapping corrugation 16 ascompared to the walls 36 of underlying corrugation 32.

This in turn means that the instant panels and the building coveringprovided thereby can be used in varying climates and conditions ofinstallations including on-site locations where severe winds areencountered and which produce severe uplifting loads on the panels inthe joint area.

In the deep trusslike joint structure formed by the lapping andoverlapping sheets or panels 10 of the instant invention,

- the steep rib angle of subtending walls 25 of corrugation 16 relativeto walls 36 of corrugation 32 results in the mergence of these walls atthe bottom of joint 1 and provides for the formation of air pockets,which act in conjunction with the five points of Contact A, B, C, D andE between the overlapped panels 10 in joint 1 to provide five individualseal points and twin antisiphon chambers 46 and 48 that resist forcedwater seepage in the joint structure 1. The result is an efficientweatherproof and sealed joint.

The pocket 2 in outermost corrugation .16 provides a convenientarrangement whereby a corrugation 16 will be properly guided intoposition about and into overlapping relationship and registry with theunderlying corrugation 32 in the respective overlapped panels 10 thatform joint 1.

In the usual nailing operation, as the nail fastener 42 is driventhrough the sheets, the ribs or corrugations 16 and 32 may tend to flexor flatten a slight amount under the pressure exerted by the nailingelements 42. This flattening action can be advantageous, however, inthat it will tend to wedge the top portion of an underlying corrugation32 into a snug fit within the pocket 2 of a double crested corrugation16 while at the same time slightly defecting the inwardly tensionedoutermost or free wall 25 of corrugation 16 provided with the lip 26outwardly. This outward deflection of the aforesaid free wall 25 and lip26 on one panel 10 causes a retensioning of the same against theassociated wall 36 of the underlying corrugation 32 of the underlyingpanel 10 thereby ensuring the maintenance of line or surface-to-surfacecontact between this lip-26 and the fiat surface of the underlying panel'10 and also compensating for any tolerances that may exist in lip orflange 26 as a result of panel manufacture. When panel 10 is made froman aluminum base alloy in the extra hard temper range as noted above,the spring-back characteristics exhibited by such a panel are used toadvantage in that the inwardly tensioned outermost wall 25 of acorrugation 16 of one panel will tend to be even more retensionedagainst an underlying wall 36 of another underlying panel 10.

The particular lapped joint structure 1 of the instant invention makesit possible to conveniently lap the ends of the sheets or panels 10 insuperadjacent 'or upper rows on the wall or roof of a building structureprovided with such panels with the sheets or panels in the higher rowsbeing generally disposed over top the sheets or panels in the lower rowsand without breaking the overall continuity of the joints 1 formed byseveral superposed rows of sheets or panels.

An advantageous embodiment of the invention has been shown anddescribed. It is obvious that various changes may be made thereinwithout departing from the attached claims, wherein:

What is claimed is:

1. A corrugated building panel of the type described and provided withmarginal side edges having different configurations one of said marginalside edges comprising a double crested corrugation, the outermost crestof said corrugation providing a primary flat narrow nailing crest andsaid primary crest being connected by outwardly and downwardly disposedsidewalls to a secondary and relatively wide flat crest thatsubstantially parallels the underside of the panel and projects to eachside of the primary crest, the ends of said wide crest terminating indownwardly and outwardly inclined sidewalls that are substantiallylonger than said first mentioned sidewalls while being located atgreater interior angles to the median plane of the panel than said firstmentioned sidewalls, and the opposing marginal side edge of the panelwhich is adapted upon installation to be overlapped by the doublecrested corrugation of a similarly configured panel being provided witha flat topped corrugation that terminates in outwardly and downwardlyinclined sidewalls that are longer than and are inclined at smallerinterior angles to the median plane of the panel than the longersidewalls of the double crested corrugation and the outermost sidewallof each of said marginal side edge corrugations having an outwardlyprojecting lip portion and the outermost sidewall of the double crestedcorrugation of the panel being overbent inwardly so that it can besealingly tensioned against a wall of a corrugation of another buildingpanel that it overlaps upon being installed on a building structure.

2. A corrugated building panel of the type defined in claim 1 and madefrom an aluminum base alloy in the extra hard temper.

3. A corrugated building panel of the type defined in claim 1 and madefrom an aluminum base alloy in the extra hard temper wherein at leastone of the longer walls of the double crested corrugation is inclined atan interior angle on the order of 65 to the bottom of the panelcontaining said corrugation.

4. A corrugated building panel of the type defined in claim 1 and madefrom an aluminum base alloy in the extra hard temper wherein the wallsof the corrugation that is to be overlapped by a similarly shaped panelare disposed at interior angles of about 56 to the bottom of thecorrugated panel.

5. A corrugated building panel of the type set forth in claim 1 whereinthe short walls of the double crested corrugation are disposed atinterior angles of about 60 to the median plane of the panel.

6. A lap joint for roofing sheets and the like comprised of a pair ofsuch sheets arranged in overlapping relationship at the marginal sideedges thereof to form a deep truss-like joint structure, the overlappingside marginal edge of the upper sheet having a double crestedcorrugation whereby it is pro vided with a primary narrow and stiffenedoutermost flat nailing crest and a secondary substantially wider flatcrest that substantially parallels the underside of the upper sheet andprojects to each side of and is connected to said primary crest byangularly outwardly and downwardly disposed sidewalls, the the ends ofsaid wider crest terminating in downwardly and outwardly inclinedsidewalls that are substantially longer than said first mentionedsidewalls while being disposed at greater interior angles to the medianplane of their associated sheet than said first mentioned sidewalls,said primary crest and first mentioned sidewalls providing a pocket forsnugly receiving the crest of the corrugation of the underlying andlapped edge portion of the lower sheet and the corrugation of theunderlying sheet.having a flat crest the edges of which terminate indownwardly and outwardly disposed sidewalls that are longer than thelonger sidewalls of and generally parallel the short sidewalls of thefirst mentioned and lapping sheet at the upper portion thereof and whichconverge fully with and sealingly contact the longer sidewalls of thelapping sheet at the bottom portion thereof and each of the outermostwalls of the interfitting corrugations of the lapped and lapping sheetshaving an outwardly projecting lip portion that sealingly engages anopposing sheet.

7. A lap joint as set forth in claim 6 wherein said lapped and lappingsheets contact each other at a plurality of points while also beingspaced from each other in selected areas that provide antisiphoningchambers in the joint.

8. A lap joint as set forth in claim 6 where at least one of saidroofing sheets is made from an aluminum base alloy in the extra hardtemper and the longer walls on said double crested corrugation of saidone roofing sheet are inclined at interior angles on the order of 65 tothe bottom of the sheet containing such double crested corrugation.

9. A lap joint as set forth in claim 6 wherein at least one of saidroofing sheets is made from an aluminum base alloy in the extra hardtemper and the walls on the corrugation of the lapped sheet are disposedat interior angles of about 56 to the bottom of said lapped sheet.

10. A lap joint as set forth in claim 6 wherein at least one of saidsheets is made from an aluminum base alloy in the extra hard temperrange.

1. A corrugated building panel of the type described and provided withmarginal side edges having different configurations one of said marginalside edges comprising a double crested corrugation, the outermost crestof said corrugation providing a primary flat narrow nailing crest andsaid primary crest being connected by outwardly and downwardly disposedsidewalls to a secondary and relatively wide flat crest thatsubstantially parallels the underside of the panel and projects to eachside of the primary crest, the ends of said wide crest terminating indownwardly and outwardly inclined sidewalls that are substantiallylonger than said first mentioned sidewalls while being located atgreater interior angles to the median plane of the panel than said firstmentioned sidewalls, and the opposing marginal side edge of the panelwhich is adapted upon installation to be overlapped by the doublecrested corrugation of a similarly configured panel being provided witha flat topped corrugation that terminates in outwardly and downwardlyinclined sidewalls that are longer than and are inclined at smallerinterior angles to the median plane of the panel than the longersidewalls of the double crested corrugation and the outermost sidewallof each of said marginal side edge corrugations having an outwardlyprojecting lip portion and the outermost sidewall of the double crestedcorrugation of the panel being overbent inwardly so that it can besealingly tensioned against a wall of a corrugation of another buildingpanel that it overlaps upon being installed on a building structure. 2.A corrugated building panel of the type defined in claim 1 and made froman aluminum base alloy in the extra hard temper.
 3. A corrugatedbuilding panel of the type defined in claim 1 and made from an aluminumbase alloy in the extra hard temper wherein at least one of the longerwalls of the double crested corrugation is inclined at an interior angleon the order of 65* to the bottom of the panel containing saidcorrugation.
 4. A corrugated building panel of the type defined in claim1 and made from an aluminum base alloy in the extra hard temper whereinthe walls of the corrugation that is to be overlapped by a similarlyshaped panel are disposed at interior angles of about 56* to the bottomof the corrugated panel.
 5. A corrugated building panel of the type setforth in claim 1 wherein the short walls of the double crestedcorrugation are disposed at interior angles of about 60* to the medianplane of the panel.
 6. A lap joint for roofing sheets and the likecomprised of a pair of such sheets arranged in overlapping relationshipat the marginal side edges thereof to form a deep truss-like jointstructure, the overlapping side marginal edge of the upper sheet havinga double crested corrugation whereby it is provided with a primarynarrow and stiffened outermost flat nailing crest and a secondarysubstantially wider flat crest that substantially parallels theunderside of the upper sheet and projects to each side of and isconnected to said primary crest by angularly outwardly and downwardlydisposed sidewalls, the the ends of said wider crest terminating indownwardly and outwardly inclined sidewalls that are substantiallylonger than said first mentioned sidewalls while being disposed atgreater interior angles to the median plane of their associated sheetthan said first mentioned sidewalls, said primary crest and firstmentioned sidewalls providing a pocket for snugly receiving the crest ofthe corrugation of the underlying and lapped edge portion of the lowersheet and the corrugation of the underlying sheet having a flat crestthe edges of which terminate in downwardly and outwardly disposedsidewalls that are longer than the longer sidewalls of and generallyparallel the short sidewalls of the first mentioned and lapping sheet atthe upper portion thereof and which converge fully with and sealinglycontact the longer sidewalls of the lapping sheet at the bottom portionthereof and each of the outermost walls of the interfitting corrugationsof the lapped and lapping sheets having an outwardly projecting lipportion that sealingly engages an opposing sheet.
 7. A lap joint as setforth in claim 6 wherein said lapped and lapping sheets contact eachother at a pluraliTy of points while also being spaced from each otherin selected areas that provide antisiphoning chambers in the joint.
 8. Alap joint as set forth in claim 6 where at least one of said roofingsheets is made from an aluminum base alloy in the extra hard temper andthe longer walls on said double crested corrugation of said one roofingsheet are inclined at interior angles on the order of 65* to the bottomof the sheet containing such double crested corrugation.
 9. A lap jointas set forth in claim 6 wherein at least one of said roofing sheets ismade from an aluminum base alloy in the extra hard temper and the wallson the corrugation of the lapped sheet are disposed at interior anglesof about 56* to the bottom of said lapped sheet.
 10. A lap joint as setforth in claim 6 wherein at least one of said sheets is made from analuminum base alloy in the extra hard temper range.